Optimum OPTimill F 150 Operating Manual
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Optimum OPTimill F 150 Operating Manual

Cnc-milling machine
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OPTIMUM
M A S C H I N E N - G E R M A N Y
Operating manual
Version 1.1.6
CNC-milling machine
GB

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Summary of Contents for Optimum OPTimill F 150

  • Page 1 OPTIMUM M A S C H I N E N - G E R M A N Y Operating manual Version 1.1.6 CNC-milling machine...

  • Page 2: Table Of Contents

    OPTIMUM M A S C H I N E N - G E R M A N Y Table of contents Safety Glossary of symbols ..........................7 Safety instructions (warning notes)......................7 1.2.1 Classification of hazards .......................7 1.2.2 Other pictograms...........................8 Intended use .............................9 Reasonably foreseeable misuses......................9...
  • Page 3 OPTIMUM M A S C H I N E N - G E R M A N Y 2.16 Tools and tool holding fixtures....................... 27 Assembly and commissioning Dimensions of the packing ........................28 Scope of delivery............................ 28 Transport ..............................28 Storage..............................
  • Page 4 OPTIMUM M A S C H I N E N - G E R M A N Y 6.2.1 Operating the handwheel for manual travelling ................72 Switching on the CNC machine ......................73 Switching off the CNC machine ......................74 First insertion of a tool ...........................74 Insert tool ..............................74...
  • Page 5 Dear customer, Thank you very much for purchasing a product made by OPTIMUM. OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions and convince by an outstanding price performance ratio. Continuous enhancements and product innovations guarantee state-of-the-art products and safety at any time.
  • Page 6 If you have any further questions after reading these operating instructions and you are not able to solve your problem with a help of these operating instructions, please contact your specialised dealer or directly the company OPTIMUM. Optimum Maschinen Germany GmbH Dr.- Robert - Pfleger - Str. 26 D-96103 Hallstadt Mail: info@optimum-maschinen.de...

  • Page 7: Safety

    OPTIMUM M A S C H I N E N - G E R M A N Y Safety This part of the operating instructions explains the meaning and use of the warning notices included in these operating instruc- ...

  • Page 8: Other Pictograms

    OPTIMUM M A S C H I N E N - G E R M A N Y In case of specific dangers, we replace the pictogram with general danger with a warning of injury of hands, hazardous electrical rotating parts.

  • Page 9: Intended Use

    We expressly point out that the guarantee or CE conformity will expire due to any constructive technical or procedural changes which had not been performed by the company Optimum Maschinen Germany GmbH. It is also part of intended use that you observe the limits of performance of the CNC-machine, ...

  • Page 10: Avoiding Misuses

    OPTIMUM M A S C H I N E N - G E R M A N Y 1.4.1 Avoiding misuses  Use of suitable cutting tools.  Adapting the speed adjustment and feed to the material and workpiece. ...

  • Page 11: Possible Dangers Caused By The Cnc Machine

    OPTIMUM M A S C H I N E N - G E R M A N Y Possible dangers caused by the CNC machine The CNC machine has undergone a safety inspection.. The construction and type are state of the art.

  • Page 12: Authorized Personnel

    OPTIMUM M A S C H I N E N - G E R M A N Y Operator The operator has been instructed by the operating company regarding the assigned tasks and possible risks in case of improper behaviour. Any tasks which need to be performed beyond the operation in the standard mode must only be performed by the operator if it is indicated in these instructions and if the operating company expressively commissioned the operator.

  • Page 13: Operator Positions

    OPTIMUM M A S C H I N E N - G E R M A N Y require personnel to confirm participation in training/instructions by means of a signature,  check whether the personnel is working safety- and risk-conscious and observe the operat- ...

  • Page 14: Lockable Main Switch

    OPTIMUM M A S C H I N E N - G E R M A N Y 1.8.1 Lockable main switch In the position " 0 " the lockable main switch can be secured against accidental or non-author- ized switching-on by means of a padlock.

  • Page 15: Emergency Stop Push Button

    OPTIMUM M A S C H I N E N - G E R M A N Y 1.8.2 EMERGENCY STOP push button ATTENTION! The EMERGENCY STOP push button immediately stops the operation of the CNC machine. Press the EMERGENCY STOP push button only if there is a risk! If this button is actuated in order to switch off the CNC machine in the standard operation the tool or workpiece might get damaged.

  • Page 16: Prohibition, Warning And Mandatory Labels

    OPTIMUM M A S C H I N E N - G E R M A N Y 1.8.5 Prohibition, warning and mandatory labels INFORMATION All warning and mandatory labels must be legible. Check them regularly. Safety check Check the CNC machine at least once per shift. Inform the person responsible immediately of any damage, defects or changes in the operating function.

  • Page 17: Personal Protective Equipment

    OPTIMUM M A S C H I N E N - G E R M A N Y 1.10 Personal protective equipment For certain work personal protective equipment is required. Protect your face and eyes: Wear a safety helmet with facial protection when performing works where your face and eyes are exposed to hazards.

  • Page 18: Safety During Maintenance

    OPTIMUM M A S C H I N E N - G E R M A N Y WARNING! When chipping magnesia materials (aluminium-/magnesium alloys) spontaneously inflammable or explosive particles (powder, dust, chips) might be generated which might result in a fire and/or an explosion (deflagration).

  • Page 19: Using Lifting Equipment

    1.15 Accident report Inform your supervisors and Optimum Maschinen Germany GmbH immediately in the event of accidents, possible sources of danger and any actions which almost led to an accident (near misses).

  • Page 20: Electrical System

    OPTIMUM M A S C H I N E N - G E R M A N Y 1.16 Electrical system Have the machine and/or the electric equipment checked regularly. Immediately eliminate all defects such as loose connections, defective wires, etc.

  • Page 21: Technical Data

    OPTIMUM M A S C H I N E N - G E R M A N Y Technical data The following information are the dimensions and indications of weight and the manufacturer‘s approved machine data. Electrical connection Total connection...

  • Page 22: Working Area

    OPTIMUM M A S C H I N E N - G E R M A N Y Working area Height [mm] 3300 Depth [mm] 3900 Width [mm] 3200 Milling table Table length [mm] Table width [mm] T - slot size / number / distance [mm] 16 / 4 / 100 Max.

  • Page 23: Working Area, Traverse Path

    OPTIMUM M A S C H I N E N - G E R M A N Y Working area, traverse path X-axis [mm] Y-axis [mm] Z-axis [mm] Standard tool changer carrousel Max. number of tool places max. tooling diameter [mm] Max.

  • Page 24: Milling Spindle Head With Use Of A Cts System

    OPTIMUM M A S C H I N E N - G E R M A N Y 2.10.2 milling spindle head with use of a CTS system Spindle seat Speed range [ min 10 -10000 2.11 Spindle capacity F150...

  • Page 25: Environmental Conditions- Operation

    M A S C H I N E N - G E R M A N Y 2.12 Environmental conditions- operation Temperature 19 - 21 °C (for an optimum milling result) 19 - 21 °C (for operation without malfunc- tions) Admissible relative humidity 5...80 % no condensation...

  • Page 26: Dimensions External Unit 20 Bar And 70 Bar

    OPTIMUM M A S C H I N E N - G E R M A N Y 2.14.2 Dimensions external unit 20 bar and 70 bar Img.2-2: 351121009 and 351121003 F150 Technical data Page 26 Original operating instructions Version 1.1.6 dated 2014-10-16...

  • Page 27: Emissions

    OPTIMUM M A S C H I N E N - G E R M A N Y 2.15 Emissions The emission of the CNC machine is below 80 dB(A). If the CNC machine is installed in an area where various machines are in operation, the noise exposure (immission) on the operator of the CNC machine at the working place may exceed 80dB(A).

  • Page 28: Assembly And Commissioning

    OPTIMUM M A S C H I N E N - G E R M A N Y Assembly and commissioning INFORMATION The CNC machine is pre assembled. It is delivered in a transport box. After the unpacking and the transportation to the installation site it is necessary to mount and assemble the individual components of the CNC-machine.

  • Page 29: Storage

    Example: not stackable - do not stack a second packing case on top of the first packaging case Consult Optimum Maschinen Germany GmbH if the CNC machine and accessories are stored for more than three months or are stored under different environmental conditions than those ...

  • Page 30: Installation Plan F150

    OPTIMUM M A S C H I N E N - G E R M A N Y Installation plan F150 Img.3-1: Installation plan Requirements regarding the installation site Organize the working area around the CNC machine according to the local safety regulations.

  • Page 31: Transportation To The Installation Site

    OPTIMUM M A S C H I N E N - G E R M A N Y Transportation to the installation site ATTENTION! The CNC machine is lifted and transported at the machine substructure or at the load suspension points using an appropriate conveyor system.

  • Page 32: Crane

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.7.2 Crane Transport device 3511201 Img.3-3: Transporting by crane If not yet available you must mount four ring bolts at the provided load application points on the machine substructure and on the column.

  • Page 33: Installation And Assembly

    OPTIMUM M A S C H I N E N - G E R M A N Y  Fix the load suspension gear (e.g. lifting slings) on the four ring bolts of the machine sub-  structure and of the column.

  • Page 34: Assembly Of The Coolant / Lubricant Tank And Of The Chip Conveyor

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.8.2 Assembly of the coolant / lubricant tank and of the chip conveyor  Push the coolant / lubricant tank below the CNC machine.

  • Page 35: Assembly Of The Coolant / Lubricant Pumps

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.8.3 Assembly of the coolant / lubricant pumps  Position the three coolant / lubricant pumps in the corresponding seat of the coolant / lubri- cant tray.
  • Page 36 OPTIMUM M A S C H I N E N - G E R M A N Y  Mount the coolant / lubricant hoses of the cooling lubricant equipment. The connections of the coolant / lubricant hoses have a designation, parts with the same designation belong together.
  • Page 37 OPTIMUM M A S C H I N E N - G E R M A N Y  Mount the spiral hose incl. the cleaning gun. Cleaning gun Connection Cleaning gun Img.3-15: Cleaning gun  Mount the oil separator of the coolant / lubricant tank.
  • Page 38 OPTIMUM M A S C H I N E N - G E R M A N Y  Connect the connector plugs of the coolant / lubricant pumps and of the chip conveyor, as well as the coolant / lubricant hoses of the coolant / lubricant tank. Make sure that the plug connections are correctly connected.

  • Page 39: Mounting The Optional Coolant Through Spindle

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.8.4 Mounting the optional coolant through spindle CTS - Coolant Through Spindle ATTENTION! CTS the external system can be used only with a specific mixing ratio of the refrigeration lubricant.

  • Page 40: Mounting The Heat Exchanger On The Switch Cabinet

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.8.5 Mounting the heat exchanger on the switch cabinet  Mount the heat exchanger onto the switch cabinet - if it had been disassembled since it is transported.

  • Page 41: Transport Locking Devices

    OPTIMUM M A S C H I N E N - G E R M A N Y Transport locking devices ATTENTION! The machine is equipped with transport locks. Before performing the electrical connection it is necessary to remove the transport locks.

  • Page 42: Transport Locking Device, Axes

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.9.3 Transport locking device, axes  Remove the transport lockings on the 3 axes X Y Z. Img.3-25: Transport lock X-axis Img.3-26: Transport lock Z-axis Img.3-27: Transport lock Y-axis...

  • Page 43: Mounting The Telescopic Covers

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.9.4 Mounting the telescopic covers  Mount the telescopic covers on the axis. Telescopic covers Img.3-28: Telescopic covers milling table  "Frästisch - Milling table 2- 2“ on page 127 3.9.5 Corrosion protection...
  • Page 44 OPTIMUM M A S C H I N E N - G E R M A N Y ATTENTION! Under extreme circumstances and depending on the quality of the network it may lead to interferences caused by the machine. If necessary and in order to exclude retroactive effects on the internal power supply system, the operator should install a line filter on the machine.

  • Page 45: Connection Compressed Air Supply

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.9.7 Connection compressed air supply The compressed air maintenance unit is positioned behind the central lubrication unit.  Open the cover on which the central lubrication unit is located.

  • Page 46: First Commissioning

    OPTIMUM M A S C H I N E N - G E R M A N Y Pneumatic diagram from year of construction 2014 Tool changer Air blow forward / backward Tool clamp / unclamp Air purge Air blow...

  • Page 47: Refill Central Lubrication System

    OPTIMUM M A S C H I N E N - G E R M A N Y Respect the environment when disposing of any lubricants and coolants. Follow the manufacturer’s disposal instructions.  "Cooling lubricants and tanks“ on page 108 3.11...

  • Page 48: Warming Up The Machine

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.11.2 Warming up the machine ATTENTION! If the CNC machine and in particular the milling spindle are immediately operated at maximum load when cold, this may result in damages.

  • Page 49: Data Backup On The Control

    OPTIMUM M A S C H I N E N - G E R M A N Y 3.11.4 Data backup on the control INFORMATION The CNC control only provides a "transient working memory" for its internal machine programs losing its contents at the latest after 3 weeks.

  • Page 50: General Information About Cnc

    OPTIMUM M A S C H I N E N - G E R M A N Y General information about CNC Compensation of geometry It is necessary to be able to measure any currently actual position of the CNC-controlled axis in order to perform tool moves on workpieces.The measured value is related to a machine fixed...

  • Page 51: Polar Coordinate System

    OPTIMUM M A S C H I N E N - G E R M A N Y 4.2.2 Polar coordinate system In the Cartesian coordinate system a point is described by e.g. its X- and Y-coordinate. For rotation-symmetric outlines, e.g. circular drilling images the required coordinates can only be calculated with considerable effort.

  • Page 52: Rotary Axes And Secondary Axes

    OPTIMUM M A S C H I N E N - G E R M A N Y 4.2.5 Rotary axes and secondary axes NC machines with rotary table or swivel head Rotary axis: A B C Positive turn around X, Y, Z (right- hand-rule)

  • Page 53: Trigonometric Functions

    OPTIMUM M A S C H I N E N - G E R M A N Y Rectangular triangle The rectangular triangle has a special meaning in the analytic geometry as the sides of such a triangle are having a definite mathematic relation to one another.

  • Page 54: User Interface, Machine Control Panel

    OPTIMUM M A S C H I N E N - G E R M A N Y User interface, machine control panel Screen arrangement Excerpt from the manual of the operating instructions for "SINUMERIK 828 D" Img.5-1: Screen arrangement 1.

  • Page 55: Key Definition Of The Cnc Full Keyboard

    OPTIMUM M A S C H I N E N - G E R M A N Y Key definition of the CNC full keyboard Excerpt from the manual of the operating instructions for "SINUMERIK 828 D". Img.5-2: Control panel 1.
  • Page 56 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 828 D" Function <NEXT WINDOW> • Toggles between the windows. • For a multi-channel view or for a multi-channel functionality, switches within a channel gap between the upper and lower window.
  • Page 57 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 828 D" Function <PAGE DOWN> + <SHIFT> In the program manager and in the program editor, from the cursor position, selects directories or program blocks up to the end of the window.
  • Page 58 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 828 D" Function <Cursor down> • Editing field Moves the cursor downwards.
  • Page 59 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 828 D" Function <END> + <CTRL> + <SHIFT> Moves the cursor to the last entry in the last line of the actual column or to the end of a program.
  • Page 60 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 828 D" Function <CTRL> + <F> Opens the search dialog in the machine data and setting data lists, when loading and saving in the MDI editor as well as in the program <F>...
  • Page 61 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 828 D" Function <CTRL> + <ALT> + <S> Creates a complete archive on an external data carrier <S>...
  • Page 62 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 828 D" Function <Minus> • Closes a directory, which contains the element.
  • Page 63 OPTIMUM M A S C H I N E N - G E R M A N Y Excerpt from the manual of the operating instructions for "SINUMERIK 828 D" Function <OFFSET> - only OP 010 and OP 010C Calls the "Parameter" operating area.

  • Page 64: Controls On The Machine Control Panel

    OPTIMUM M A S C H I N E N - G E R M A N Y Controls on the machine control panel Img.5-3: Machine Control Panel Elements on the MCP Element Function <EMERGENCY STOP button> Activate the button in situations where •...
  • Page 65 OPTIMUM M A S C H I N E N - G E R M A N Y Elements on the MCP Element Function <CYCLE STOP> The key is also referred to as NC Stop. Execution of a program is stopped.
  • Page 66 OPTIMUM M A S C H I N E N - G E R M A N Y Elements on the MCP Element Function Function not used in the standard delivery. Option - Coolant through spindle Command M7 = Coolant through spindle "On"...
  • Page 67 OPTIMUM M A S C H I N E N - G E R M A N Y Elements on the MCP Element Function <Spindle - Stop> It is not possible to activate the system in the automatic mode. <Spindle CCW>...
  • Page 68 OPTIMUM M A S C H I N E N - G E R M A N Y Elements on the MCP Element Function Increases or reduces the programmed speed. The programmed spindle speed is set to 100% and can be controlled from 50 to 120%.

  • Page 69: Key Switch

    OPTIMUM M A S C H I N E N - G E R M A N Y Elements on the MCP Element Function 5.3.1 Key switch <1> <2> <3> Access rights of three keys: possible Key colour Position access stage No key required <0>...
  • Page 70 OPTIMUM M A S C H I N E N - G E R M A N Y F150 Page 70 Original operating instructions Version 1.1.6 dated 2014-10-16...

  • Page 71: Operation

    OPTIMUM M A S C H I N E N - G E R M A N Y Operation Safety Commission the CNC machine only under the following conditions: The CNC machine is in proper working order.  The CNC machine is used as prescribed.

  • Page 72: Operating The Handwheel For Manual Travelling

    OPTIMUM M A S C H I N E N - G E R M A N Y Designation Touch-switch to release and clamp the tool Milling table Milling spindle Signal lamp (if the signal lamp is illuminated --> CNC- program is running)

  • Page 73: Switching On The Cnc Machine

    OPTIMUM M A S C H I N E N - G E R M A N Y Switching on the CNC machine When switching on the machine the integrated safety functions of the machine "Safety Integrated" are checked and scanned. Please proceed in the following sequence: ...

  • Page 74: Switching Off The Cnc Machine

    OPTIMUM M A S C H I N E N - G E R M A N Y Switching off the CNC machine  Push the EMERGENCY STOP push button.  For a long-term standstill of the CNC machine switch it off at the main switch.
  • Page 75 OPTIMUM M A S C H I N E N - G E R M A N Y Push button Img.6-4: Manual tool change  When inserting a tool for the first time, please observe "First insertion of a tool“ on page 74 In case that you are working using the tool changer and you would like to insert new tools you must change to the operating mode <JOG>...

  • Page 76: Manual Operation Of The Tool Changer

    OPTIMUM M A S C H I N E N - G E R M A N Y Manual operation of the tool changer 6.7.1 Manual operation of the 16-type tool changer The operator can manually travel the tool changer to the reference point ...

  • Page 77: Setting

    OPTIMUM M A S C H I N E N - G E R M A N Y Setting INFORMATION For the setup operation <JOG> (JOG operation) the sliding door for the separating protective equipment can be opened. In the setting mode resp. if the sliding door is open it is necessary to actuate the acknowledgement button in order to expressively allow the movement of the individual axes.

  • Page 78: Setting Resp. Measuring Tool

    OPTIMUM M A S C H I N E N - G E R M A N Y Img.6-6: Set workpiece datum X axis resp. Y axis  Press the button "Zero offset".  Press the key "Set NPU" after determining the workpiece datum of the corresponding axis.
  • Page 79 OPTIMUM M A S C H I N E N - G E R M A N Y  Actuate the button "Measure tool".  Travel the spindle (Z axis) to the pressure sensor (by means of the handwheel) until the indicated value is "0".

  • Page 80: Operational Modes

    OPTIMUM M A S C H I N E N - G E R M A N Y Operational modes Manually controlled operation The manually controlled operation is allowed in the operating mode "JOG" and in the operating mode "MDA". Refer to chapter 5 "Manually controlled operation" of the instructions "SINU- MERIK 828 D".

  • Page 81: Operating The Central Lubrication System

    OPTIMUM M A S C H I N E N - G E R M A N Y CAUTION! Before starting the programs you have to close the sliding door of the separating protective equipment.  Completely close the separating protective equipment.

  • Page 82: Data Interfaces And Current Collection

    OPTIMUM M A S C H I N E N - G E R M A N Y Designation Specification Act Time Timer controlled by the timer Interval Time Current consumption 2.5 A Motor Phases Power 12 W max. delivery flow...

  • Page 83: Executing From An External Position

    OPTIMUM M A S C H I N E N - G E R M A N Y 6.14 Executing from an external position Excerpt from the manual of the operating instructions for "SINUMERIK 828 D". 12.13 EXTCALL It is possible to access the files on the local drive , USB data carrier or networks using the command EXTCALL .

  • Page 84: Code List, M Functions

    OPTIMUM M A S C H I N E N - G E R M A N Y M - code list, M functions S / O S = Standard O = Option Function S / O The following code list are the manufacturer-spe- cific M-codes of the machine.

  • Page 85: G Function According To Pal

    OPTIMUM M A S C H I N E N - G E R M A N Y S / O S = Standard O = Option S / O S = Standard O = Option Function S / O...

  • Page 86: Notes, Messages And Error Messages

    OPTIMUM M A S C H I N E N - G E R M A N Y Notes, messages and error messages All messages and alarms are displayed in plain text on the operator panel. The alarm text con- tains the date, time and a suitable symbol for the cancel criterion.
  • Page 87 OPTIMUM M A S C H I N E N - G E R M A N Y Number Message description Tool data error 700028 possible rem- • Check tool table! Machine control panel error (MCP) 700030 possible rem- Check type / MD / connection.
  • Page 88 OPTIMUM M A S C H I N E N - G E R M A N Y Number Message description Asup2 execution error. 700083 Magazine rotation error. 700084 Magazine to home error. 700085 Magazine motor overloaded 700086 Arm motor overloaded 700087 Unclamp tool manually to confirm empty spindle for safety.
  • Page 89 OPTIMUM M A S C H I N E N - G E R M A N Y Number Message description Spindle controlled by PLC 700157 Change phases on main electrical connection 700158 PLC-Alarm (DB1600.DBX19.7) 700159 Tool clamp/unclamp sensor fault.
  • Page 90 OPTIMUM M A S C H I N E N - G E R M A N Y Number Message description Manual tool unclamp disabled, stop spindle and program first. 700207 Magazine referencing . . . 700210 Magazine jog disabled, close door/reset program.
  • Page 91 OPTIMUM M A S C H I N E N - G E R M A N Y Number Message description Maintenance Task 8 Alarm 700246 Maintenance Task 8 Message 700247 Notes, messages and error messages F150 Version 1.1.6 dated 2014-10-16...

  • Page 92: Sinumerik 828 D

    OPTIMUM M A S C H I N E N - G E R M A N Y SINUMERIK 828 D The instructions for the use of the SIEMENS control "SINUMERIK 828 D" is composed of the following items which are listed at the end of these operating instructions or separately attached to the machine.

  • Page 93: Maintenance

    OPTIMUM M A S C H I N E N - G E R M A N Y Maintenance In this chapter you will find important information about Inspection  Maintenance  Repair  of the CNC machine The diagram below shows you which tasks belongs to which term.

  • Page 94: Safety

    OPTIMUM M A S C H I N E N - G E R M A N Y The company Optimum Maschinen Germany GmbH does not assume any guarantee on subse- quent damages due to unsuitable cooling lubricants. The flashpoint of the emulsion must be higher than 140°C.

  • Page 95: Preparation

    If the repairs are carried out by qualified technical personnel, they must follow the indications given in these operating instructions. The company Optimum Maschinen Germany GmbH does not take any liability nor does it guar- antee against damage and operating malfunctions resulting from failure to observe this operat- ing instructions.

  • Page 96: Inspection And Maintenance

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.4 Inspection and maintenance The type and level of wear depends to a large extent on the individual usage and operating conditions. Any indicated intervals therefore are only valid for the corresponding approved con- ditions.
  • Page 97 OPTIMUM M A S C H I N E N - G E R M A N Y Check Interval Where? What? How?   "Data backup on the control“ on page 49 Oil all bare steel surfaces. Use an acid-free oil, Oiling e.g.
  • Page 98 OPTIMUM M A S C H I N E N - G E R M A N Y Check Interval Where? What? How?  Check Check the wipers on the slides. Replacing Replace if damaged immediately.  Cleaning "Cleaning electrical cabinet“ on page 101 Inspection Connections on the servo motors.
  • Page 99 OPTIMUM M A S C H I N E N - G E R M A N Y Check Interval Where? What? How?   "Obligations of the operating company“ on page 12  "Electrical system“ on page 20 Electrical inspection ...

  • Page 100: Disassembly Of The Cooling Lubricant Tank

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.4.1 Disassembly of the cooling lubricant tank The coolant / lubricant tank can be completely extracted from below the CNC machine for cleaning purposes.

  • Page 101: Cleaning Electrical Cabinet

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.4.3 Cleaning electrical cabinet Although the electrical cabinet is con- structed to shut off external air, foreign parti- cles such as dust and dirt may enter the cabinet when the door is open.

  • Page 102: Drain Compressed Air Service Unit

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.4.5 Drain compressed air service unit The filtration of water and other impurities in the compressed air is automatic when com- pressed air flows through the maintenance unit.

  • Page 103: Refill Central Lubrication System

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.4.8 Refill central lubrication system The central lubrication system supplies important functionally parts of the CNC machine. With too low level warning is the No. 700 162 .

  • Page 104: 10Cleaning Of Oil Tank And Oil Filters On The Central Lubrication System

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.4.10Cleaning of oil tank and oil filters on the central lubrication system  Remove the lubricating oil tank. Pay attention not to spill the lubricating oil when removing the tank.

  • Page 105: Optional Cts System

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.5 Optional CTS system Wher Check Interval What? How?   Fill with coolant when the level reaches the minimum level. ...

  • Page 106: Cleaning And Replacing The Filters On The External Cts System

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.5.1 Cleaning and replacing the filters on the external CTS system If the filters of CTS system are clogged, cavitation is generated. Cavitation could damage the piping and pump.

  • Page 107: Cleaning And Replacing The Filters On The Internal Cts System

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.5.2 Cleaning and replacing the filters on the internal CTS system The internal CTS system is supplied with the coolant of the machine.

  • Page 108: Cooling Lubricants And Tanks

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.6 Cooling lubricants and tanks CAUTION! The cooling lubricant can cause diseases. Avoid direct contact with cooling lubricant or parts covered in cooling lubricant.

  • Page 109: Inspection Plan For Water-Mixed Cooling Lubricants

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.6.1 Inspection plan for water-mixed cooling lubricants Company: No.: Date: used cooling lubricant size to be checked Inspection methods Inspection Procedure and comment...

  • Page 110: Network

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.7 Network 10.8 Data interfaces and current collection When connecting data interfaces make sure that the data cable runs to the interface of the con- trolwithin shortest possible distance.
  • Page 111 OPTIMUM M A S C H I N E N - G E R M A N Y Press the button "Menu advance", until it appears on the horizontal softkey bar "Licenses". Machine configuration Machine Axis Motor Drive Index Name...
  • Page 112 OPTIMUM M A S C H I N E N - G E R M A N Y  Press the button "Licenses" and then "All options". Licensing: Overview options Serial number of CF card: Missing Hardware type: lic./opt. License key is sufficient!
  • Page 113 OPTIMUM M A S C H I N E N - G E R M A N Y  Press the button "HMI button". If you cannot see the HMI icon it is necessary to enter the user password first.
  • Page 114 OPTIMUM M A S C H I N E N - G E R M A N Y  Press the buttons "Menu select" and "Diagnostics".  Press the button "Menu advance", until "Bus TCP/IP" appears on the horizontal softkey bar.

  • Page 115: Executing From An External Position

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.10 Executing from an external position Excerpt from the manual of the operating instructions for "SINUMERIK 828 D". 12.13 EXTCALL It is possible to access the files on the local drive , USB data carrier or networks using the command EXTCALL .

  • Page 116: Adjusting The Amount Of Oil At The Central Lubrication

    OPTIMUM M A S C H I N E N - G E R M A N Y 10.11 Adjusting the amount of oil at the central lubrication The amount of oil is controlled by PLC. ATTENTION! An incorrectly setting of the timer can leads to a wear of the guideways and the wipers.
  • Page 117 OPTIMUM M A S C H I N E N - G E R M A N Y Configure Lubrication Lubrication Configuration: Lubrication PLC Controlled: in seconds Lubrication OFF Time: Lubrication On Time: in seconds in seconds Last configuration Cancel Img.10-12: Lubrication configuration...

  • Page 118: Mechanische Ersatzteile - Mechanical Spare Parts

    OPTIMUM M A S C H I N E N - G E R M A N Y Mechanische Ersatzteile - Mechanical Spare parts 11.1 Ersatzteilbestellung - Ordering spare parts Bitte geben Sie folgendes an - Please indicate the following : Seriennummer - Serial No.

  • Page 119: Fräskopf - Milling Head

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.4 Fräskopf - Milling head Abb.11-1: Fräskopf - Milling head Mechanische Ersatzteile - Mechanical Spare parts F150 DE | GB Version 1.1.6 2014-10-16...
  • Page 120 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteilliste Fräskopf - Spare part list milling head Artikel- Menge Grösse Bezeichnung Designation nummer Qty. Size Item no. Innensechskantschraube Socket head screw M8xP1.25x25L...

  • Page 121: Säule - Column

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.5 Säule - Column Abb.11-2: Säule - Column Mechanische Ersatzteile - Mechanical Spare parts F150 DE | GB Version 1.1.6 2014-10-16 Original operating instructions...
  • Page 122 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteilliste Säule - Spare part list column Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Spindle head Spindle head...

  • Page 123: Maschinenunterbau - Machine Stand

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.6 Maschinenunterbau - Machine stand Abb.11-3: Maschinenunterbau - Machine stand Mechanische Ersatzteile - Mechanical Spare parts F150 DE | GB Version 1.1.6 2014-10-16...
  • Page 124 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteilliste Maschinenunterbau - Spare part list machine stand Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Substructure Base 035112102 01...

  • Page 125: Frästisch - Milling Table 1- 2

    11.7 Frästisch - Milling table 1- 2 Abb.11-4: Frästisch- Milling table 1- 2...
  • Page 126 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteilliste Frästisch - Spare part list milling table 1- 2 Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Teleskopabdeckung...

  • Page 127: Frästisch - Milling Table 2- 2

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.8 Frästisch - Milling table 2- 2 Abb.11-5: Frästisch- Milling table 2- 2 Ersatzteilliste Frästisch - Spare part list milling table 2- 2...

  • Page 128: Baugruppe X-Achse - Assembly X- Axis

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.9 Baugruppe X-Achse - Assembly X- Axis Abb.11-6: Baugruppe X-Achse - Assembly X-Axis DE | GB F150 Mechanische Ersatzteile - Mechanical Spare parts Original operating instructions Version 1.1.6 2014-10-16...
  • Page 129 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteilliste Baugruppe X-Achse - Spare part list assembly X-Axis Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Lock nut Nutmutter YSR M25xP1.5...

  • Page 130: Baugruppe Y-Achse - Assembly Y- Axis

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.10 Baugruppe Y-Achse - Assembly Y- Axis Abb.11-7: Baugruppe Y-Achse - Assembly Y-Axis DE | GB F150 Mechanische Ersatzteile - Mechanical Spare parts Original operating instructions Version 1.1.6 2014-10-16...
  • Page 131 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteilliste Baugruppe Y-Achse - Spare part list assembly Y-Axis Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Nutmutter Lock nut YSR M25xP1.5...

  • Page 132: Baugruppe Z-Achse - Assembly Z- Axis

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.11 Baugruppe Z-Achse - Assembly Z- Axis Abb.11-8: Baugruppe Z-Achse - Assembly Z-Axis DE | GB F150 Mechanische Ersatzteile - Mechanical Spare parts Original operating instructions Version 1.1.6 2014-10-16...
  • Page 133 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteilliste Baugruppe Z-Achse - Spare part list assembly Z-Axis Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Nutmutter Lock nut YSR M25xP1.5...

  • Page 134: Maschinengehäuse - Machine Housing

    11.12 Maschinengehäuse - Machine housing Abb.11-9: Maschinengehäuse - Machine housing...

  • Page 135: Späneförderer - Chip Convejor

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.13 Späneförderer - Chip convejor Abb.11-10: Späneförderer - Chip convejer Ersatzteilliste Späneförderer - Spare part list chip convejor Quan- Size Item number...

  • Page 136: 16-Fach Werkzeugwechsler - 16-Station Tool Changer

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.14 16-fach Werkzeugwechsler - 16-station tool changer 11.14.1Werkzeugwechsler 1-4 - Tool changer 1-4 Abb.11-11: Werkzeugwechsler 1-4 -Tool changer 1-4 DE | GB...
  • Page 137 OPTIMUM M A S C H I N E N - G E R M A N Y Ersatzteilliste Werkzeugwechsler 1-4 - Spare part list tool changer 1-4 Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Baugruppe Zylinder...

  • Page 138: 2Werkzeugwechsler 2-4 -Tool Changer 2-4

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.14.2Werkzeugwechsler 2-4 -Tool changer 2-4 Abb.11-12: Werkzeugwechsler 2-4 -Tool changer 2-4 Ersatzteilliste Werkzeugwechsler 2-4 - Spare part list tool changer 2-4 Quan-...
  • Page 139 OPTIMUM M A S C H I N E N - G E R M A N Y Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Schraube Screw Schraube Screw Scheibe Washer Scheibe Washer Federscheibe Spring washer...

  • Page 140: 3Werkzeugwechsler 3-4 -Tool Changer 3-4

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.14.3Werkzeugwechsler 3-4 -Tool changer 3-4 Abb.11-13: Werkzeugwechsler 3-4 -Tool changer 3-4 Ersatzteilliste Werkzeugwechsler 3-4 - Spare part list tool changer 3-4 Quan-...

  • Page 141: 4Werkzeugwechsler 4-4 -Tool Changer 4-4

    OPTIMUM M A S C H I N E N - G E R M A N Y Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Magazinteller Magazine plate 0351121012 09 Aufnameplatte Magazin Monting plate on magazine...
  • Page 142 OPTIMUM M A S C H I N E N - G E R M A N Y Quan- Size Item number Bezeichnung Designation tity Qty. Size Item no. Nockenscheibe Cam disk 0351121013 10 Sensorhalter Sensor bracket 0351121013 11 Welle...

  • Page 143: Optionaler 24-Fach Werkzeugwechsler - Optional 24-Station Tool Changer

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.15 Optionaler 24-fach Werkzeugwechsler - Optional 24-station tool changer 11.15.1Werkzeugwechsler 1 von 5 - Tool changer 1 of 5 Abb.11-15: Werkzeugwechsler - Tool changer...

  • Page 144: 2Werkzeugwechsler 2 Von 5 - Tool Changer 2 Of 5

    OPTIMUM M A S C H I N E N - G E R M A N Y Artikel- Menge Grösse Bezeichnung Designation nummer Qty. Size Item no. Zugentlaster Cable fixed 03511210 1427 Zugentlaster Cable fixed 03511210 1428 11.15.2Werkzeugwechsler 2 von 5 - Tool changer 2 of 5 Abb.11-16: Werkzeugwechsler - Tool changer...

  • Page 145: 3Werkzeugwechsler 3 Von 5 - Tool Changer 3 Of 5

    OPTIMUM M A S C H I N E N - G E R M A N Y Artikel- Menge Grösse Bezeichnung Designation nummer Qty. Size Item no. Bolzen Bolt 03511210 1519 11.15.3Werkzeugwechsler 3 von 5 - Tool changer 3 of 5 Abb.11-17: Werkzeugwechsler - Tool changer...

  • Page 146: 4Werkzeugwechsler 4 Von 5 - Tool Changer 4 Of 5

    OPTIMUM M A S C H I N E N - G E R M A N Y Artikel- Menge Grösse Bezeichnung Designation nummer Qty. Size Item no. Ring Ring 03511210 1820 Buchse Bushing 03511210 1821 Bolzen Bolt 03511210 1822...

  • Page 147: 5Werkzeugwechsler 5 Von 5 - Tool Changer 5 Of 5

    OPTIMUM M A S C H I N E N - G E R M A N Y Artikel- Menge Grösse Bezeichnung Designation nummer Qty. Size Item no. Gewindestift Set screws 03511210 1615 Schraube Screw 03511210 1616 Schraube Screw 03511210 1617...
  • Page 148 OPTIMUM M A S C H I N E N - G E R M A N Y Artikel- Menge Grösse Bezeichnung Designation nummer Qty. Size Item no. Platte Plate 03511210 1713 Pnuematik Zylinder Air cylider 03511210 1714 Klotz Block...

  • Page 149: Integriertes Kühlaggregat 20 Bar - Integrated Cooling Unit 20 Bar

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.16 Integriertes Kühlaggregat 20 bar - Integrated cooling unit 20 bar Abb.11-20: Integriertes Kühlaggregat 20 bar - Integrated cooling unit 20 bar...

  • Page 150: Externes Kühlaggregat 20 Bar - External Cooling Unit 20 Bar

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.17 Externes Kühlaggregat 20 bar - External cooling unit 20 bar Abb.11-21: Externes Kühlaggregat 20 bar - External cooling unit 20 bar...

  • Page 151: Externes Kühlaggregat 70 Bar - External Cooling Unit 70 Bar

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.18 Externes Kühlaggregat 70 bar - External cooling unit 70 bar Abb.11-22: Externes Kühlaggregat 70 bar - External cooling unit 70 bar...

  • Page 152: Ec - Declaration Of Conformity

    OPTIMUM M A S C H I N E N - G E R M A N Y 11.19 EC - Declaration of Conformity Machinery Directive 2006/42/EC Annex II 1.A Optimum Maschinen Germany GmbH The manufacturer / Dr.-Robert-Pfleger-Str. 26 retailer:...

  • Page 153: Ec - Declaration Of Conformity Siemens

    OPTIMUM M A S C H I N E N - G E R M A N Y EC - Declaration of Conformity SIEMENS EC - Declaration of Conformity SIEMENS F150 Version 1.1.6 dated 2014-10-16 Original operating instructions Page 153...

  • Page 154: Appendix 13.1 Copyright

    Appendix 13.1 Copyright Optimum Maschinen Germany GmbH This document is copyright. All derived rights are reserved, especially those of translation, re- printing, use of figures, broadcast, reproduction by photo-mechanical or similar means and recording in data processing systems, either partial or total.

  • Page 155: Liability Claims For Defects / Warranty

    V-belts, ball bearings, illuminants, filters, sealings, etc. - Non reproducible software errors Any services which OPTIMUM GmbH or one of its agents performs in order to fulfill in the  frame of an additional guarantee are neither an acceptance of the defects nor an accept- ance of its obligation to compensate.

  • Page 156: Decommissioning

    OPTIMUM M A S C H I N E N - G E R M A N Y 13.5.1 Decommissioning CAUTION ! Immediately decommission used machines in order to avoid later misuse and endangering of the environment or of persons.

  • Page 157: Disposal Of Lubricants And Coolants

    OPTIMUM M A S C H I N E N - G E R M A N Y 13.5.5 Disposal of lubricants and coolants ATTENTION! Please imperatively make sure to dispose of the used coolant and lubricants in an environmentally compatible manner. Observe the disposal notes of your municipal waste management companies.

  • Page 158: Re-Export

    Any forwarding of contract products to the customer by third parties with or without knowledge of Optimum Maschinen Germany GmbH requires at the same time the transfer of the export authorization conditions. The customer shall be completely liable in case of non-observance of the relevant conditions.

  • Page 159: Terminology/Glossary

    OPTIMUM M A S C H I N E N - G E R M A N Y 13.9 Terminology/Glossary Term Explanation Cross table, milling table Bearing surface, clamping surface for the workpiece with X- and Y-axis travel C omputer A ided D esign...

  • Page 160: Change Information Operating Manual

    OPTIMUM M A S C H I N E N - G E R M A N Y 13.10 Change information operating manual Chapter Short note new version number 10.5 Axis-specific values 1.1.1 Recommended compressed air quality 1.1.2 01:11 Function signal lamp 1.1.3...
  • Page 161 OPTIMUM M A S C H I N E N - G E R M A N Y Index Main switch ...........14 Maintenance ............. 108 Accident report ............19 Maintenance, Inspection ........93 Alarms ..............86 Measuring feed ..........110 Assembly Mechanical maintenance work ......19 of the chip conveyor ........34...
  • Page 162 OPTIMUM M A S C H I N E N - G E R M A N Y Working area ..........21 Tool commissioning ..........74 Tool changer manual operation .......... 76 Transport locking devices ........41 Using lifting equipment ........19 Working area ............

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